4.

5 INDEX OF CHEMICAL PROCESS QUANTITATIVE RISK ASSESSMENTS

NO. TITLE I INDUSTRY NO. & TYPE OF RECORDS DATA BOUNDARY PAGE

4.5-1 Hazardous Waste Tank Failure Chemical Process Failure rates from published sources or expert Storage tanks 57.
judgment
4.5-2 Risk Analysis of Six Potentially Hazardous Chemical Process Limited failure data from one plant and published Pumps and piping, valves, measuring devices, 58.
Industrial Objects in the Rijnmond Area; A data source failure rates controllers and transmitters, electrical, and
Pilot Study vessel data
4.5-3 CANVEY: An Investigation of Potential Chemical Process Event frequencies estimated from historical Event and equipment failure data for analysis of 59.
Hazards from Operations in the Canvey data; failure rates from System Reliability nine industrial plants and hazardous material
Island/Thurrock Area Service transport
 CHEMICAL PROCESS QRAS
TITLE:
Hazardous Waste Tank Failure
SPONSOR/AUTHOR:
US EPA
INDUSTRY: TIME FRAME:
Through 1985
I NO.:
4.5-1

Chemical Process
TYPE: FREQUENCY OF UPDATE:
Report None
NUMBER AND TYPE OF RECORDS: Failure rates from published sources or
expert judgment

DATA BOUNDARY: Storage tanks

DATA ACCESS:
Contact: National Technical Information Service (NTIS)
Springfield, VA 22161
Phone: (703) 487-4650
Report No.: PB86-192945
Cost: $50.95

DESCRIPTION:
This report documents an extensive study of the likelihood of failure
and release of hazardous materials from storage tanks. The report includes
a fault tree analysis of a "generic" tank and the quantification of
the probability of a release. A lengthy computer program (232 pages of
Fortran code) for simulation of incidents is included in the report. In term
of reliability data, the report includes a listing of failure probabilities
used in the analysis in Table 13. The data sources used and the means by which
the data in Table 13 were derived are detailed in Appendix A. The report does
not include new, experience based data. Most of the data was taken from other
published sources. The gaps were filled in with "engineering estimates" and
"personal communications" with various groups such as the Portland Cement
Association. This detailed PRA may be of use to the CPI not so much because
of the data, but because of its extensive treatment of vessel and pipe
leak and rupture probabilities.
 CHEMICAL PROCESS QRAS
TITLE: Risk Analysis of Six Potentially Hazardous Industrial Objects in
the Rijrimond Area; A Pilot Study
SPONSOR/AUTHOR:
Dutch Labor Directorate
INDUSTRY: TIME FRAME:
I NO.:
4.5-2

Chemical Process Through 1981

TYPE: FREQUENCY OF UPDATE:
Book None
NUMBER AND TYPE OF RECORDS: Limited failure data from one plant and
published data source failure rates

DATA BOUNDARY: Pumps and piping, valves, measuring devices, controllers

and transmitters, electrical, and vessel data

DATA ACCESS:
Report Title: Risk Analysis of Six Potentially Hazardous Industrial
Objects in the Rijnmond Area; A Pilot Study (1982)
Report No.: ISBN-90-277-1393-6
Ordering Address: Kluwer Academic Publishers
P.O. Box 358, Accord Station, Hingham, MA 02018-0358
Phone: (617) 871-6600, Customer Service Department
Cost: $165; no postage charge if pre-paid order

DESCRIPTION:
The Rijnmond area is that part of the Rhine delta between Rotterdam and the
North Sea. The Commission for the Safety of the Population at large (COVO)
commissioned the study for six chemicals and the operations associated with
them: acrylonitrile, liquid ammonia, liquid chlorine, LNG, propylene, and part
of a* separation process (diethanolamine stripper of a hydrodesulfurizer) . The
study objectives were to evaluate methods of risk assessment and obtain
experience with practical applications of these methods. The results were to
be used to decide to what extent such methods can be used in formulating safety
policy. The study was not concerned with the acceptability of risk or the
acceptability of risk reducing measures.

The book contains only a small amount of actual failure data from one of the
study plants. One year's worth of data is described for acrylonitrile storage
tank instrumentation (level and temperature) , plus some assessment of hose
failures. The remaining base failure rate data are contained in Appendix IX of
the report with references to the sources of data, many of which are commonly
cited data sources. The data are classified under Pumps and Piping, Valves,
Measuring Devices, Controllers and Transmitters, General Electrical, and
Vessels. Correction factors were applied to these base data before using in fault
trees, etc, to account for environment, maintenance, and operating philosophy
as judged by the risk assessment team.
 CHEMICAL PROCESS QRAS
TITLE: CANVEY: An Investigation of Potential Hazards from Operations in
the Canvey Island/Thurrock Area
SPONSOR/AUTHOR:
UK Health & Safety Commission
INDUSTRY: TIME FRAME:
I NO.:
4.5-3

Chemical Process Through 1977

TYPE: FREQUENCY OF UPDATE:
Report None
NUMBER AND TYPE OF RECORDS: Event frequencies estimated from historical
data; failure rates from System Reliability Service.

DATA BOUNDARY: Event and equipment failure data for analysis of nine
industrial plants and hazardous material transport.

DATA ACCESS:
Report Title: CANVEY: An Investigation of Potential Hazards from Operations
in the Canvey Island/Thurrock Area
(Essex, U. K)
Ordering Address: H. M. Stationery Office
P.O. Box 569
London, England SEl 9NH

DESCRIPTION:

This study investigated risks to the public from serious accidents which could
occur at the industrial facilities in this part of Essex, U.K. Results
are expressed as risk to an individual and societal risk from both existing
and proposed installations. Risk indices were also determined for modified
versions of the facilities to quantify the risk reduction from recommendations
in the report. Nine industrial plants were analyzed along with hazardous
>material transport by water, road, rail and pipeline. The potential toxic,
fire and explosion hazards were assessed for flammable liquids, ammonia, LPG,
LNG, and hydrogen fluoride (HF) . The 24 appendices to the report cover various
aspects of the risk analysis. These include: causes and effects of unconfined
vapor cloud explosions; fire impacts; dispersion of ammonia, HF, and heavy gas;
and pressure vessel failure rates.

The report does not contain original data, only references to sources
of information. Frequencies were estimated for events from historical data
and by incorporating failure rate data from the System Reliability Service.
Event frequencies and equipment failure rates in the report are coded to
indicate the confidence level of the data. In particular, the coding reflects
whether the data is (a) assessed statistically from historical data, (b) based
on statistics but reflecting some judgment, (c) estimated by comparison to
previous cases for which fault tree analysis have been made, and (d) "dummy"
figures — where subjective judgement must be made even though there is
likely to be large uncertainly in the values.
4.6 INDEX OF NON-PROCESS EQUIPMENT DATA BASES
NO. TITLE I INDUSTRY NO. & TYPE OF RECORDS DATA BOUNDARY PAGE

4.6-1 Centralized Reliability Data Organization Nuclear 1800 Component failure events causing Liquid metal reactor sites and test facility 62.
Input Guide abnormal operation; engineering data for systems and components
20,000 components found in liquid metal
reactors (e.g., LMRs). Gives generic data for 45
equipment items (valves, pumps, etc.)
4.6-2 Nuclear Plant Reliability Data System Nudear Engineering data from all U.S. NPP (currently Voluntary reporting of engineering information 64.
91 plants); failure data describing 44,000 and failures for selected systems and
events components as defined in a reportable scope
manual
4.6-3 The£uropean Reliability Data System: An Nuclear Comprehensive records on equipment U.S. & European nuclear reactor data on 65.
Organized Information Exchange on the failure, frequency, modes, unusual events, and equipment performance, repair and
Operation of European Nuclear Reactors plant production maintenance
4.6-4 Determination of Reliability Characteristic Nuclear Failure rates with upper and lower bounds and Data for pumps, valves, and electrical 66.
Factors in the Nudear Power Plant Biblis B, maintenance data for 1 7,000 components from positioning devices, electric motors and drives
Gesellschaft fur Reaktorsicherheit mbH 37 safety systems from an operating power plant
4.6-5 Generating Availiability Data System Power System and equipment failure data from 2,600 All types of major electrical power generating 68.
electric power units giving failure rates, modes, equipment which could cause a full or partial
mean time to repair, mean time between outage of an electrical generating utility
outages
4.6-6 Reliability Data Book for Components in Power, Nuclear 30,000+ recorded events Safety and commercial grade components, i.e. 70.
Swedish Nuclear Power Plants pumps, valves, dieseis, filters, tanks, and heat
exchangers from 4 nuclear and non nuclear
power generating plants
4.6-7 Failure and Inventory Reporting System Offshore Oil and 8,000 failure events and causes; Inventory data Safety and pollution prevention devices on 72.
Natural Gas on ASME coded devices offshore structures, e.g. subsurface safety
valves
4.6-8 Government Industry Data Exchange Pro- Varied Recorded historical, experimental, and test Engineering, Reliability, Metrology, and Failure 73.
gram (GIDEP) data from 650 participating agencies/industries. data on mechanical, electronic and electrical
May include failure frequencies, rates, modes, components
mechanisms as well as repair times
4.6-9 System Reliability Service Varied Status reports contain failure, repair, and A wide variety of equipment failure and 75.
maintenance data on 450 categories; data sets performance records from utilities and
are broader manufacturers, plus collected inspection data
4.6-10 SAIC Data Base Nudear Plant maintenance and repair records by system Data mainly for pumps, valves, dieseis, 76.
and component type; selected basic event batteries, chargers, and heat exchangers
failure rates and unavailability
4.6 INDEX OF NON-PROCESS EQUIPMENT DATA BASES |

NO. TITLE INDUSTRY NO. & TYPE OF RECORDS DATA BOUNDARY PAGE I

4.6-11 The In-Plant Reliability Data Base for Nuclear
Nudear Plant Components
4.6-12 IEEE Standard 500-1 984 Nuclear
4.6-13 Generic Data Base for Data and Models Nuclear
Chapter of the National Reliability
Evaluation Program Guide
4.6-14 Offshore Reliability Data Handbook Offshore Oil
4.6-15 RADC Non-Electronic Reliability Notebook Military
4.6-16 Reliability Prediction of Electronic Government
Equipment (Military Handbook 217E) Military
Corrective maintenance records: 4000 for Pumps, valves, dieseis, battery chargers, and 78.
pumps; 581 2 for valves; 698 for electrical failure inverters from 4 nuclear power plants
rates and modes.
Over 100 data sheets, containing failure rate Electrical, instrumentation, and mechanical 80.
estimates for various failure modes and some components in nudear power plants
repair times.
Estimates of hourly and per demand failure rates Standard nuclear plant PRA equipment list 82.
for 20 categories with error factors generated by
experts
Failure rates based on 14,000 failures for 300 Offshore oil equipment data and boundaries for 84.
component types. Mean values, upper and lower safety systems, process systems, electrical
bounds are offered for different failure modes. systems, utility systems, cranes and drilling
equipment.
Failure rates based on operations and Covers 250 non-electronic part types such as 87.
maintenance records and industry-wide sources actuators, complings, filters for 1 2 classes of
environment (air, ground, sea) used in military
systems and equipment.
and Failure rates for 13 categories of components. Electronic components used in military 89.
electronic systems and equipment.
 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
Centralized Reliability Data Organization Input Guide
SPONSOR/AUTHOR: U.S. DOE and Japan's Power NO.:
Reactor and Nuclear Fuel Development Corp. (PNC) 4.6-1
INDUSTRY: TIME FRAME:
Nuclear 1960 to present
TYPE: FREQUENCY OF UPDATE:
Data Base and Report Quarterly
NUMBER AND TYPE OF RECORDS: 1800 component failure events causing abnormal
operation; engineering data for 20, 000 components found in liquid metal reactors
(e.g., LMRs). Gives generic data for 45 equipment items (valves, pumps, etc.)
DATA BOUNDARY: Liquid metal reactor sites and test facility systems and
components

DATA ACCESS:
Contact: Mr. H. E. Knee, Oak Ridge National Laboratory, Bldg. 6205, ms-360
P.O. Box 2008, Oak Ridge, TN 37831-6360
Phone: (615) 574-6163 (FTS 624-6163)
Data accessibility: Limited

DESCRIPTION:
The Centralized Reliability Data Organization (CREDO) is maintained at ORNL
to provide a central computer-based source of accurate, timely data and
information for use in reliability, availability and maintainability
analyses of liquid metal reactors (LMRs) . CREDO is a component-based system,
that addresses a comprehensive list of 45 generic components that are
representative of all components found at LMRs.

The data base management system used for CREDO catalogs and stores data in
three types of files that correspond to their respective data types: (a)
Engineering Data; data and information on a component's design and operating
characteristics, (b) Operating Data; A Chronological sequence of reactor
operating experience, per reactor mode, (c) Event Data; data on abnormal
operating events that are attributable to a component, including event
descriptions, method of detection, failure mode/cause, and corrective action.

The CREDO data base contains data from The Fast Flux Test Facility in Richland,
Washington, The Experimental Breeder Reactor - II in Idaho Falls, Idaho, The
test loops of the Energy Technology Engineering Center (ETEC) in Canoga Park,
California, The JOYO Liquid Metal Fast Breeder Reactor at the 0-Arai Engineering
Center (OEC) in Japan, and the test loops of OEC.
Data Resource 4.6-1
Centralized Reliability Data Organization Input Guide
Example Data Sheet

EVENT DATA REPORTING FORM (CREDO-I, Rev. l)

 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
Nuclear Plant Reliability Data System

SPONSOR/AUTHOR: NO.:
Institute of Nuclear Power Operations (INPO) I 4.6-2
INDUSTRY: TIME FRAME:
Nuclear 1974 to Present

TYPE: FREQUENCY OF UPDATE:

Data Base and Reports Continuous

NUMBER AND TYPE OF RECORDS: Engineering data from all U.S. NPP
(currently 91 plants); failure data describing 44,000 events

DATA BOUNDARY: Voluntary reporting of engineering information and failures

for selected systems and components as defined in a reportable scope manual

DATA ACCESS:
Contact: Keith Pope, INPO, 1100 Cir. 75 Pkwy, Ste 1500, Atlanta, GA 30339
Phone: (404) 953-5443
Report ordering address: Same as above, For annual summaries of data base for
1978-19BO: GPO Sales Program, Div. of TIDC, U.S. NRC, Washington, D. C. 20555
Report Cost: Free to INPO members/participants;
NRC access is $145 per connect hour
Report accessibility: Summary reports available; Limited specific reports.
Computer access: Limited, as with report access
DESCRIPTION:
The NPRDS is an industry-wide system for monitoring the performance of selected
systems and components at U.S. commercial nuclear power plants. Information
in NPRDS is derived from a standardized format input report prepared by
U.S. nuclear plant licensees. The plants are asked to submit failure reports
on catastrophic events and degraded failures within the defined reportable
scope; reporting of incipient events is optional. Command faults are not
reportable unless they make an entire system unavailable. In addition, the
plants are asked to file component engineering reports on all components within
the ' selected systems and reportable scope. These reports contain detailed
design data, operating characteristics, and performance data on the selected
systems and components (over 3000 components, from approximately 30 systems,
per unit). The selected systems are primarily safety systems.

NPRDS data are available to users, either through annual summary reports
(to resume publication in the coming year) or through direct on-line data
base access from a computer terminal. Special reports and listings are
available through specific requests for extraction or data analysis.

Although the reporting period covers approximately 12 years, the most detailed
reporting has been implemented by most of the licensees since 1984 when the
new LER rule came into effect and fewer component failures were reported to
the LER system. One should note that no human-error-related data are included
in the data bank except for actions that cause broken hardware.

NPRDS data can be obtained in the form of magnetic tapes or floppy disks that
are dBASE III or LOTUS 1-2-3 compatible.
 NON-PROCESS EQUIPMENT DATA BASES
TITLE: The European Reliability Data System: An Organized Information
Exchange on the Operation of European Nuclear Reactors

SPONSOR/AUTHOR: NO.:
European Economic Community 4.6-3
INDUSTRY: TIME FRAME:
Nuclear Early 1970' s to Present
TYPE: FREQUENCY OF UPDATE:
Data Base Every 6 months

NUMBER AND TYPE OF RECORDS: Comprehensive records on equipment failure,

frequency, modes, unusual events, and plant production

DATA BOUNDARY: U.S. & European nuclear reactor data on equipment

performance, repair and maintenance

DATA ACCESS:
Contact: G. Mancini
Sector Head-Nuclear Installations Engineering Division
Ispra Establishment
1-21020 Ispra (Varese)
Italy
Phone: (0332) 789714
(Telex: 380042 EURI)
DESCRIPTION:
The ERDS is comprised of four data banks:

1. The Component Event Data Bank contains raw data on component failure,
reliability, and operating modes, from EEC countries, Spain, and Sweden.

2. The Abnormal Occurrences Reporting System contains unusual plant events

and human factors associated with normal operation from the U.S., Sweden,
and all relevant ECC countries except Germany (discussions are in progress
there) .

3. The Operating Unit Status Report contains production and outage

log information on power reactor operation from ECC countries, Spain,
and Switzerland.

4. The Generic Reliability Parameter Data Bank is a bibliography of reliability

information for plants with similar classes of components.

The ERDS attempts to establish a uniform method of encoding the types of data
submitted from the various entities. Inconsistencies of detail are monitored
automatically by the data bank computer services.

The data are very comprehensive with direct applications to reliability, risk,
and event analysis of nuclear power plants. Information has been assembled
on failure frequency, modes, repairs, and maintenance. Rate information is
based on demands calculated. The time period covered varies from the early
1970rs to the present. Using real time access, the output format if the
event can be varied by selection of 20 generic and detailed categories.
 NON-PROCESS EQUIPMENT DATA BASES
TITLE: Determination of Reliability Characteristic Factors in the Nuclear
Power Plant Biblis B f Gesellschaft fur Reaktorsicherheit mbH

SPONSOR/AUTHOR: NO.:
RWE 4.6-4
INDUSTRY: TIME FRAME:
Nuclear 1977 to Present
TYPE: FREQUENCY OF UPDATE:
Data Base Continuous

NUMBER AND TYPE OF RECORDS: Failure rates with upper and lower bounds and
maintenance data for 17,000 components from 37 safety systems.

DATA BOUNDARY: Data for pumps, valves, electrical positioning devices,

electric motors and drives from an operating power plant

DATA ACCESS:
Contact: P. Homke
Gesellschaft fur Reaktorsicherheit mbH
Glockengasse 2.5000
KoIn I, West Germany (FRG)
Phone: (02-21) 20 68-1
Report Cost: Free to authorized users of the data base

DESCRIPTION:
The German Gesellschaft fur Reaktorsicherheit (GRS) has a private arrangement
with Rheinische Westalisches Elekrizitatswerke (RWE) to compile reliability
data from an operating power plant, Biblis B. The data base contains failure
rate, maintenance, and operational event data. External event data
(floods, earthquake, fire, etc.) are compiled through a separate utility-
sponsored data base. The data base provides information on repair and
maintenance, and equipment performance.

This data collection effort was concentrated on the following components because
of their extensive populations and repair action documentation: pumps, valves,
electrical positioning devices, electric motors, and drives. For each component
type, preface pages and data summary tables are provided. Separate data summary
tables are provided for each component type and are structured in a format that
allows for the inclusion of the number of pieces of operating equipment,
the total number of operating hours, total number of failures, and hourly
failure rates with upper and lower bounds.

All of the information listed directly above is correlated to an all damages

mode, individual subcategories of failure modes (internal leakage, for
instance), and the influence parameters and their subdivisions. Real-
time access is possible through a data base management system.
Data Resource 4.6-4
Determination of Reliability Characteristic Factors
in the Nuclear Power Plant Biblis
Example Data Sheet

TADLBi SUMMARY OP
TU
FAILURE RATES PORi regulation damper (KAP)1 controlled SHEETiI

description
No. of
pieces of
oper.
equipt.
sum of
hours
No. of
operating failures M*
10
h^
2*
h
Xio
10
h^
damage typei all damage B 169 2,535tOOO 30 8.5 11. B 15-9
all damages with non-
availability during repair 169 2,535tOOO 25 6.8 9.8 13.7
AM fc 03
failure model does not open and/or close
BM - type average 169 2, 535 »000 25 6.8 9-8 13.7
influence parameter i
system (reaotor ventilation) TL 21 3l5tOOO 9 14.9 28.6 49.8
(air-cond. and ventilation) UV 148 2,22O9OOO 16 4.5 7.2 11
utilization modei (continuous operation) 9* 1,'11O9OOO 14 6 9.9 15-4
(cyclic operation) 5 75»ooo 4 18.1 530 122
(stand-by operation) 70 1.050,000 7 3-2 6.7 12.6
 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
Generating Availability Data System
SPONSOR/AUTHOR: NO.:
NERC 4.6-5
INDUSTRY: TIME FRAME:
Power Mid-1960' s to Present
TYPE: FREQUENCY OF UPDATE:
Data Base and Reports Quarterly

NUMBER AND TYPE OF RECORDS: System and equipment failure data from 2, 600
electric power units giving failure rates, modes, mean time to repair, mean time
between outages.
DATA BOUNDARY: All types of major electrical power generating equipment
which could cause a full or partial outage of an electrical generating utility

DATA ACCESS:
Contact: Ronald Niebo, Director
North American Electric Reliability Council
101 College Road East, Princeton, NJ 08540-6601
Phone: (609) 452-8060
Report Cost: Free to GADS Participants
Data accessibility: General information available as annual or quarterly status
reports
DESCRIPTION:
The NERC GADS encompasses 2, 600 electric power units, including nuclear, fossil,
hydro, and combined cycle. The data base is comprised of safety or commercial
quality components, 25 percent electronic and 75 percent mechanical. There
are over a million individual and statistically reduced events, encoded
in a structured extended text format. Historically, system transients and
external initiating events have been grouped together. Beginning in 1982, the
categories started being reported separately. Data supplied to GADS have been
recorded by the electric utilities participating in the GADS program.
All generic categories of components are included if their failure caused
a forced, scheduled, or partial plant outage. The data are statistically
reduced to derive failure frequency rates, modes, mechanisms, and intervals
using calculated population and demands. Also considered are the mean repair
time and equipment downtime.

The NERC GADS ten-year review report for 1971-1980 on equipment availability
presents statistical data sets on the performance of major types of electrical
power generating units. Cumulative and unit.-year averages are calculated on
such quantities as service hours, available hours, scheduled outage rate,
mean time between full forced outages, shutdown because of economic
reasons, and probability of outage. The number of start demands and successful
starts are included.

The ten-year review for 1971-1980 of the NERC GADS component cause code report
documents all outages attributed to each of the component cause codes.
Data Resource 4.6-5
Generating Availability Data System
Example Data Sheet

Fossil Units - All Fuel Types

All SiZe RangeS 1983-1987 u^s DUE TO OUTACPS AND DERATING*
BY CAUSE COI)K CATtGOKIES

FORCED AND SCHEDULED !

FORCED DOTAGES FORCED DERATlNGS OUTAGES AND DERATINGS
CAUSE SYSTEM /COMPONENT
CODE CAUSE CODE AVG NO AVG MWH AVG HRS AVG NO AVC EQV AVG EQV AVG NO AVG EQV AVG EQV
RANGES CATEGORIES OCC PER PER PER OCC PER HWH PER MRS PCR OCC ,PER MWH PER HRS PER
UNlT-YR Jfctt-**
ONtt*Yt U OHtT-YR UNtT-YR ONtf-YR lWlt*YR UWlT-YR UNlT-YR

0010-1999 BOILER 4.84 70232 212.2 6.93 27187 Sl .91 2.05 265355 833.18
0010-0480 0.46 7302 7.3 11 .84 744;4 24 - 58 13.93 14794 50.90
0010-0110 ..Coal Hand. Equip, up Thru Bunkers 0.02 506 1 .0 0.77 657 35.1 0.83 1314 3.27
0200-0350 O. 10 525 29.38
0360-0410 0.23 R74 2.8 0.56 347 1.50 0.88 3243 12.47
0415-0435 . .Cyclone 0.02 109 0.4 0.40 159 0.53 0.45 580 2 . 44
0440-0480 O. IO 2S9 1 .5 0.17 320 O. 79 0.30 853 3.34
0500-0799 .Boiler Piping Syot. -m O. 33 5010 12.8 0.81 1781 5.30 1.40 12817 38.57
0500-0530 . .Mnin Stenm 0.08 1584 4.2 0.14 231 1 .05 0.32 3465 12-07
0540-0570 ..Cold and Hot Rc.-heat Steam 0.01 1085 2.2 0.21 585 1 .29 0.26 3170 8.28
0580-0620 . . Desuperheaters/At trinpi-rn turps 0.03 271 0.8 O. 14 132 0.36 0.20 700 2.26
0630-0660 ..Startup Bypass 0.05 734 1.2 0.03 8} 0.13 0.09 1402 .44
0.04 314 1 .0 0.04 42 O. 19 O. 11 706 .56
0.07 622 1 . 7 0 . 24 684 2.20 0.36 1787 .24
0775-0799 ..Miscellaneous Piping 0.03 400 1 .5 0.01 23 0.09 0 . 06 1586 .72
O. 10 1691 5.0 0.15
860-0920 -Slag and Ash Removal 0.05 684 1 .9 0.61 543 1.37 0.79 2111 .04
000-1090 .Bo UtT Tube Leaks 2.76 50955 156.8 0 . 60 1143 4..'42 3.88 61673 19 .87
100-1200 O. OS 1754 5.2 1.05 1 715 4.43 1.27 5268 I .60
300-1350 0.02 380 1 .2 0.06 315 I. 10 O. 15 7513 2 .54
0.38 3864 11 .0 2.71 9956 26.93 3 . 36 22738 6 .64
400-1 '4 50 . .AIr Supply O. 15 1446 3.7 0.82 3563 10. 15 1.11 6204 1 .05
455-1530 . .Flue Cas 0.22 2266 6.6 1.71 6098 16.13 2.22 15083 4 . 74
535-1580 0.01 87 0.4 0.04 190 0.45 0.06 581 .94
590-1599 ..Miscellaneous (A r Supply) 0.01 64 0.2 O. 14 104 0.20 0-17 870 .92
0.55 2433 6.5 0.63 472 1. 30 1.28 4469 1 .65
800-1820 0.01 434 2*. 1 0.05 131 0.37 0.73 121418 37 .27
850-1850 .Boiler Water Cond tlon 0.03 159 0.6 2.18 2451 7.40 2. 35 2822 .69
900-1910 .Boiler Design Lim tations 0.00 20 0.0 0.05 353 0.69 0.06 546 .26
980-1999 .Miscellaneous (Bn ler) 0.08 547 1.4 0,40 485 2.05 0.69 4931 1 .39

1.39 14248 40.7 8.27 19823 58. 15 12 .64 52627 16 .61

110-3199 . Condensing System 0.25 1813 5.6 2.34 1905 6.12 4. 24 7152 2 .35
110-3119 . .Condenser Tubes 0.10 908 3.0 1.90 1489 4.68 3-55 4553 1 .50
120-3129 ..Condensing Cas inp./Shel I f. Internals 0.02 526 1 .2 0.05 85 0.24 O. 10 963 .7.
130-3149 ..Vacuum Equipment 0.11 252 0.9 0.26 203 0.64 0.38 499 .85
0.01 18 0.0 0.01 13 0.26 0.03 38 .37
170-3199 ..Miscellaneous (Condensing System) 0.01 108 0.4 O. 12 114 0.30 0.19 1099 .92
210-3299 0.08 860 4.0 0.73 1692 5.86 1.01 4531 2 .37
3310-3399 O. II 902 J. U 0.94 2524 7.27 1.20 5119 1 .67
0.03 205 0.6 0.44 1753 5.04 0.57 2357 .88
0.05 508 1.21 0.22 462 1.41 0.33 2118 .11
3350-3352 ..Polishers/Chemical Addition 0.01 99 0.23 0.22 234 0.61 0.24 417 .07
3360-3399 0.01 89 0.92 0.05 74 0.21 0.07 227 .61
3401-3499 0.47 4867 12.33 3.33 12196 34.54 4.38 24295 6 .31
0.01 85 0.20 0.19 222 0.74 0.22 445 .36
3520-3529 0.02 215 0.49 0.04 140 0.45 0.08 551 .56
3600-3689 .Electrical 0.86 7527 2 .65
3810-3899 .Auxiliary Systems 0.07 434 0.93 O. 19 108 0.31 0.32 992 3.01
3810-3819 ..Service Water (Open System) 0.01 54 0.16 0.02 12 0.04 0-03 157 0.63
3820-3829 ..Closed Cooling Water Systems 0.01 34 0.12 0.02 26 0.07 0.04 166 0.64
3830-3839 0.02 239 0.39 0.13 41 0.14 0.17 445 0.93
3840-3849 . .Service Air 0.00 7 0.03 0.01 13 0.02 0.01 24 0.07
3850-3859 . -Instrument Air 0.02 53 0.14 0.02 10 0.02 0.04 90 0.39
3860-3869 0.00 12 0.03 0.00 2 0.00 0.01 19 0.05
3899-3899 0.00 35 0.07 0.00 4 0.01 0.01 92 0.30
3950-3999 .Miscellaneous (Balance of Plant) 0.02 121 0.33 0.19 303 0.64 0.33 2016 5.34

4000-4499 STEAM TURBINE 1 .22 21628 6 .23 1.81 4474 12.64 4.46 114124 378.01
4000-4099 0.09 4159 1 .51 0.18 1510 5.00 0.34 9864 36.86
4100-4199 0.02 1609 .10 0.06 165 0.37 O. 10 2599 6.00
0.07 4380 1 .75 0.25 645 1 .23 0.37 9760 26.15
4260-4269 -Valves 0.20 2167 .62 0.42 868 2.27 0.92 7005 22.48
4270-4279 •Piping 0.03 536 .50 0.02 30 0.07 0.06 857 2.56
4280-4289 -Lube Oil 0.06 1585 .27 0.01 20 0.09 O. Il 2428 7.21
4290-4309 .Controls 0.42 2186 .84 0.21 355 0.99 0.77 3920 12.04
4400 -44 99 .Miscellaneous (Steam Turbine) 0.33 5006 I .62 0.65 881 2.62 l.RO 77692 264.72

4500-4899 GENERATORS 0.53 16053 4 .34 0.50 1112 2.77 1-35 34400 97.69
4500-4590 0.09 6272 2 .62 0.09 605 1.36 0.27 12207 37.98
4600-4609 .Exciter 0.14 2747 .8 0.05 92 O. 17 0.23 3458 9.57
4610-4650 .Cooling System 0.09 2928 .1 0.24 318 0.84 0.39 4999 13.38
4700-4750 -Controls O. 16 753 2.1 0.03 30 0.08 0.24 967 2.89
0.06 3153 7.6 0.10 69 0.32 0.23 12770 33.87

8000-8699 POLLUTION CONTROL EQUIPMENT 0.09 1260 3.9 1.47 2435 6.46 1.97 12167 35.65
8000-8499 0.02 313 0.7 0.58 1171 2.54 0.75 4480 13.40
8000-8099 0.00 14 0.0 0.02 26 0.06 0.02 41 0.09
8100-8199 . .Scrubber 0.00 36 O.I 0.21 450 0.95 0.31 1253 3.01
8200-8299 0.01 154 0.3 0.21 194 0.49 0.24 842 2.27
0.00 24 0.0 0.03 63 0.19 0.04 98 0.27
8400-8499 ..Miscellaneous (Wet Scrubbers) 0.01 84 0.1 O. U 439 0.84 0.13 2246 7.76
8500-8549 -Dry Scrubbers 0.00 O 0.0 0.02 15 0.03 0.03 26 0.06
8550-8580 .Preclpitators 0.07 915 3.0 0.66 999 3.13 0.98 6834 19.82
0.00 32 0,1 0.20 250 0.76 0.22 827 2.37

9000-9320 EXTERNAL 0.13 1533 3.7 3.74 2445 8.01 3.91 5587 16.44
9000-9040 .Catastrophe 0.03 1109 2.3 0.03 39 0.27 0.06 1166 2.75
9130-9160 .Economic 0.01 107 0.60 0.07 142 0.32 0.09 1631 4.72
9200-9290 .Fuel Quality 0.04 147 0.37 3.51 2106 6.94 3.55 2271 7.39
9300-9320 .Miscellaneous (External Problems) 0.06 170 0.46 0.13 158 0.47 0.21 519 1.58

9500-9720 REGULATORY, SAFETY AND ENVIRONMENTAL 0.01 205 1.65 2.91 2825 10.09 3.01 4077 16.68
9500-9590 .Regulatory 0.00 1 0.00 O. Ol 21 0.13 0.02 460 2.29
9600-9655 .Stack Emission 0.01 111 0.87 2.61 2464 9.10 2.66 2770 11.08
9660-9696 0.00 89 0.74 0.28 337 0.85 0.32 723 2.87
9700-9720 .Safety 0.00 3 0.03 0.00 2 0.01 0.01 125 0 . 44

9900-9920 PERSONNEL ERRORS 0.29 2338 7.10 0.12 130 0.32 0.42 2656 7.91

9999-99<»9 PERFORMANCE 0.00 25 0.06 0.02 8 0.03 0.08 217 0.76

With permission of North American Electric Reliability Council.

 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
Reliability Data Book for Components in Swedish Nuclear Power Plants

SPONSOR/AUTHOR:
Swedish State Power Board
INDUSTRY: TIME FRAME:
I
I NO.:
4.6-6

Power, Nuclear 1973 to Present

TYPE: FREQUENCY OF UPDATE:
Data Base Quarterly
NUMBER AND TYPE OF RECORDS: 30,000+ recorded events

DATA BOUNDARY: Safety and commercial grade components, i.e. pumps, valves,
diesels, filters, tanks, and heat exchangers from 4 nuclear and non nuclear power
generating plants.

DATA ACCESS:
Contact: Jean-Pierre Bento
Radet Fur Karnkraft Sakerhet
Nuclear Safety Board of the Swedish Utilities
Box 5864 S-102 48
Stockholm, Sweden
Phone: 046-08-679540
(Telex: 131-08)
DESCRIPTION:

The Swedish Thermal Power Reliability Data System (ATV) is maintained

and managed by the Swedish State Power Board at Stockholm, Sweden. Engineering
and reliability data have been collected from both nuclear and nonnuclear
power generating plants. Nuclear data collection began in 1973. Collection
of reliability data began in 1976. Over 30,000 events have been recorded
in the data base.

All data recorded in the data base have been acquired from plant records.
Statistical reductions of data for generation of reports or specific end use
are available. Data are currently collected from four operating plants
(eight units) . Time clocks have been installed on components, to record actual
exposure time. Event data are available on a broad variety of safety and
commercial grade components including pumps, valves, transformers, diesels,
filters, tanks (vessels), and heat exchangers.

Real-time access to the data base is possible through a data base management
system. In addition to safety-related system data, data for interfacing
(auxiliary) system components are also available. The data base management
system provides in-depth flexibility for generation of specific output reports.
Although access has been limited to members of the Swedish Utility Consortium
and the Swedish Power Board Directorate, a Reliability Data Book is available
with generic failure rates based primarily on this data base.
 Data Resource 4.6-6
Reliability Data Book for Components
Example Data Sheet
in Swedish Nuclear Power Plants
Centrifugal pump, horisontal and vertical
Centrifugal pump, horisontal and vertical
Backgrond data

Number of components: 18
Failure mode: Failure to start Flow rate: 120-240kg/s
Number of demands: 784 (per operational time) Developed head: 1,2-1,8MPa
Number of failures: 4
Value of Alfa: 0.387 Operational mode: standby
Value of Beta: 75.4
Method of estimation: Weighted aPriori Moment Method (WPM)
Power plant Failure Active repair
to start (average)
Physical boundary of the component (10-3/demand) (h)

Barseback 1 7.0 5
Feeding directly from Barseback 2 3.3 *
main supply or sub-
supply depending on
object Forsmark 1 4.0 *

380 V Forsmark 2 4.3 *

Oskarshamn 1 11. 2

Fuse
Oskarshamn 2 2.6 *
Logic/ Control Switchyard Feeder Switch Manual Ringhals 1 2.8 *
Automation Equipment Equipment (norm ON)
for component
All BWR plants
Mean value 5.1 3
Clamping Device
Relay Contactor/Switch
95% 21.
Indi- Motor
cations Pedestal overload Component
Cable protection * No critical failures reported
overload I

Motor
Transmission
Pump
 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
Failure and Inventory Reporting System
SPONSOR/AUTHOR: NO.:
U.S. Dept . of the Interior 4.6-7
INDUSTRY: TIME FRAME:
Offshore Oil and Natural Gas 1980 to Mid-1982
TYPE: FREQUENCY OF UPDATE:
Data base None

NUMBER AND TYPE OF RECORDS: 8,000 failure events and causes; Inventory
data on ASME coded devices

DATA BOUNDARY: Safety and pollution prevention devices on offshore

structures, e.g. subsurface safety valves

DATA ACCESS:
Contact: L. E. Bennett (Gene)
Minerals Management Services (OS-2)
U.S. Department of the Interior
P.O. Box 7944
Metairie, LA 70010
Phone: (504) 736-0557

DESCRIPTION:
The Failure and Inventory Reporting System (FIRS) program was developed by
the Geological Survey Division of the U.S. Department of the Interior for safety
and pollution prevention devices on offshore structures that produce or
process hydrocarbons . The program collected data on mechanical and some electro-
mechanical systems on offshore oil platforms. About 8,000 failure events
were documented. Access has been limited to internal materials management
system use . No real-time access or periodic output products have been available .

The system was composed of two programs. The safety device inventory reporting
program provided information listing the number of safety and pollution devices
by type, manufacturer, and model. The safety device failure reporting program
provided information about the failures of these devices by failure causes,
corrective actions, device type, manufacturer, model, and frequency of failure.
Failure percentages, reliability and quality trends, mean time between repairs,
and mean time between failures, along with other statistical information,
were derived from these data.

The project was ended when financial support was discontinued; Mr. Bennett can
field questions on the data set contents.
 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
Government Industry Data Exchange Program (GIDEP)
SPONSOR/AUTHOR: NO.:
Various U.S. Government Agencies 4.6-8
INDUSTRY: TIME FRAME:
Varied 1950 's to Present

TYPE: FREQUENCY OF UPDATE:

Data base and Reports Continuous

NUMBER AND TYPE OF RECORDS: Recorded historical, experimental, and

test data from 650 participating agencies/industries. May include failure
frequencies, rates, modes, and mechanisms as well as repair times.
DATA BOUNDARY: Engineering, Reliability, Metrology, and Failure data
on mechanical, electronic and electrical components.

DATA ACCESS:
Contact: Jim Richards or George Carver
GIDEP Operations Center
Corona, CA 91720
Phone: (714) 736-4677
Data accessibility: Standard outputs on microfilm and data base access {PC
connection via modem) free to participants in GIDEP, who must agree to exchange
(input) data; keyword searches by manufacturer for report abstracts
DESCRIPTION:
The Government-Industry Data Exchange Program (GIDEP) is funded and operated
by the United States Government. GIDEP has approximately 650 participants from
U.S. government agencies and various industries. All quality levels of
components are represented with microcircuit, electronic, electrical,
electromechanical, and mechanical systems included. The collected data
specifically excludes both proprietary and confidential data; the emphasis
is on off-the-shelf items. The data base is constructed from both recorded
historical data furnished by the participants and from experimental or test
data. Various environments, depending on the component's application, are
included in the data bases; the operating environment is flagged. The failure
frequencies, failure rates, failure modes, failure mechanisms, and mean times
to repair may be included. GIDEP is comprised of four main data banks (referred
to as data interchanges) : (a) The engineering data interchange contains
engineering evaluation and qualification test reports, nonstandard parts
justification data, parts and material specifications, and other related
engineering data on parts, components, materials, and manufacturing
processes. (b) The reliability-maintainability data interchange contains
failure rate/mode and replacement rate data on parts, components, and
materials based on field performance information and/or reliability
demonstration tests of equipment, subsystems, and systems, (c) The metrology
data interchange contains metrology-related engineering data on test systems,
calibration systems, and measurement technology and test equipment calibration
procedures, (d) The failure experience data interchange contains objective
failure information generated when significant problems are identified
for parts, components, processes, fluids, materials, or safety and fire
hazards .
Data Resource 4.6-8
Government Industry Data Exchange Program
Example Data Sheet

FAILURE RATE DATA

SCt GROUP CONFIDENCE INTEPVAL
CENLRIC CCDE NOMENCLATfRC LOWER HEAN UPP6R
U
HEEL PARTICI- OBSERVED STRESS OBSERVATIOH TOTAL MILLION UNIT OF FAILURE O
IMAGE PANT PART MANUFAC- ENVIRONMENT LEVEL SCR PERIOD HRT NBR. NER. PART MEA- RATE T
NUMOER CODE NUMBER TURER WITH MODIFIER APPLICATION ES-T-MS CLS BEGINXFND MHRS FAIL PARTS HOURS SURE /MILLION E
928.55 VALVESt SEQUENCE 23.398 465.983 2210.621
FCn3-0718 AS MSL-300ST LlQ RKT ENC -M-H A 6107/7406 1 S8C C.C02216 CYCS 165.983
PREDOMINANT FAILURE MODES: DEACTUATEO PREMATURELY-2

928.toO VALVES* REGULATING OR REDUCING C.29C 0.848 1.9Ul

FQ03-0223 S8 FS22475 GCH CO GNO- RADAR -M- 6803/73C3 C <4 Q.C4855& HRS <18.870
FCOJ-0223 S8 211F8H HOKE INC GND- RADAR -M- 6803/73C3 C 3 0.12C891 HRS <7.579
FC03-0223 S8 101C-A1 ROBERTSHAU GNO- RADAR -M- 6803/7303 C 2 C.C24278 H"S <37.741
F003-C223 S8 IG DOLE VALVC GNO- RADAR -M- 6803/7303 C UC 1.882210 HRS <0.486
FOQ3-0223 SB 30*7 DCMCO INC GNO- RADAR -M- 6803/7303 O 2 C.C24278 HRS <37.7««l
FOC3-0223 S8 RlOCS VAC ELCK GNO- RADAR -M- 6803/7303 Q 3 Q. 127572 HRS <7.182

928.60 VALVES* REGULATING OR REDUCING 1.835 6*732 17.400

HLI REFER TO VOLUME ONE.

928. £C VALVES. REGULATING CR REDUCING 8C.8&6 96.111 113. «»8 181 3 . 4 8 8

FQC3-1217 JF 9668M40 G. C. JET-UNSLT ACFT-ENGINE - -M 7201/7509 3 361 0.386270 HRS 7.766
FC03-1672 04 39-170 HYORO-AIRC JET-KANND BRAKE SVS -K- 7101/7506 15 380 C. 135280 HRS 110.881
PREDOMINANT FAILURE MOOES: INTCRNAL- 9» LEAKING-4
F003-U72 04 HP9561CC-2 TCLCDYNE JET-MANNC WINGFOLD SYS -M- 7401/7506 4 761 Q. 270916 HRS IH. 764
PREDOMINANT FAILURE MODES! LEAKING-*

S28.&Q VALVES* REGULATING CR REDUCING 17.462 19. «I1C 21.523

MSL REFER TO VOLUMf ONE.

92S.&0 VALVES. REGULATING CR REDUCING 2S7.C99 353.288 429.829

SSJ REFER TC VOLUME ONE.
 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
System Reliability Service

SPONSOR/AUTHOR: NO.:
UKAEA 4.6-9
INDUSTRY: TIME FRAME:
Varied Unknown
TYPE: FREQUENCY OF UPDATE:
Data Base and Reports Continuous

NUMBER AND TYPE OF RECORDS: status reports contain failure, repair, and
maintenance data on 450 categories; data sets are broader

DATA BOUNDARY: A wide variety of equipment failure and performance records

from utilities and manufacturers, plus collected inspection data

DATA ACCESS:
Contact: System Reliability Service, UKAEA
Culcheth, Warrington, Wigshaw Lane WA3 4NE
England
Phone: (044) 925-31244 Extension 520
Report accessibility: Limited to contributors

DESCRIPTION:
The Systems Reliability Service (SYREL) Data Base is used by the United Kingdom
Atomic Energy Authority (UKAEA) Systems Reliability Service (SRS) . It contains
information from all industries, of which 20% is nuclear related. Information
is submitted by utilities, licensing authorities, and manufacturers in addition
to inspection data gathered by the SRS staff. The data base provides information
to contributors on equipment performance, reliability, and availability,
although certain aspects of manufacturing design are confidential . The data
base is updated continuously and status reports are published every two months
on 450 generic items.

Membership in SYREL entitles the user to the service of four other data banks:

1. The Accident Data Base

2. The Maloperation Data Base, covering events of less than accidents severity

3. The Event Data Store, applying specifically to nuclear power plants

but discontinued because of high cost (approximately 1000 times normal rates)

4. The Piping Data Base, with a limited amount of detailed information which
SYREL wishes to supplement with data from U.S. facilities
 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
SAIC Data Base

SPONSOR/AUTHOR: NO.:
Joseph R. Fragola 4.6-10
INDUSTRY: TIME FRAME:
Nuclear 1980 to Present
TYPE: FREQUENCY OF UPDATE:
Data Bases and Reports With new data availability

NUMBER AND TYPE OF RECORDS: Plant maintenance and repair records by

system and component type; Selected basic event failure rates and
unavailability
DATA BOUNDARY: Data mainly for pumps, valves, diesels, batteries,
chargers, and heat exchangers

DATA ACCESS:
Contact: Joseph R. Fragola
SAIC, 342 Madison Ave . , Suite 1100, NY, NY 10173
Phone: (212) 661-5780
Data Accessibility: Available for specific studies upon request
Cost: Based on hours and level of expertise required for study

DESCRIPTION:
In the course of performing reliability and risk analyses on nuclear plant
systems and components, the New York office of SAIC has constructed numerous
failure data sets. The primary (or preferred) source for the failure and repair
information in all cases has been the plants' maintenance records for
the entirety of their operating history (as available) . To create a useful
data set from these records, a series of sorts was performed that gradually
structured the information by system, component group, component type, failure
severity, failure mode, and failure cause. Hourly and demand-related failure
rates and probabilities were then compiled for the study-specific components
types and failure modes. The data is organized into folders documenting the
development path from encoded records to calculational bases/assumptions to
failure rates. Operational history for failure rate denominators is
based upon plant shutdown/operating modes, system operation patterns,
train/component interactions, testing schedules, and system diagrams.

The SAIC New York office houses five encoded data sets of the type described
above and partial and raw data sets from five other plants. SAIC also maintains
a published data source library from various industries. This library has
been used to compile generic data sets for PRA screening, supplementing weak
areas in plant-specific data sets, and as a basis for comparing plant data
with world experience.

SAIC' s data bank focuses on pumps, valves, and other common major components,
but due to its depth has also been applied to studies on items such as strainers
and bursting discs. Access is based on the scope of work and the estimated
labor hours required to search and sort the data.
Data Resource 4.6-10
SAIC Data Base
Example Data Sheet

CARP •• DATA ANALYSIS SUMMARY REPORT

Type Code Component Failure Mode Unit Dist Mean Lower Median Upper P1 P2 Basis

AC A AIR COOLING UNIT FAILS TO START N L 2.08-04 9.44-06 8.52-05 7.69-04 9.02+00 G

AC F AIR COOLING UNIT FAILS TO RUN H L 9.05-06 1.09-06 5.55-06 2.82-05 5.08+00 G

AD F AIR DRYER FAILS TO DELIVER FLOW H L 5.23-07 3.38-07 5.07-07 7.61-07 1.50+00 G

AF F AIR FILTER FAILS TO DELIVER FLOW H L 7.23-06 1.16-06 4.91-06 2.08-05 4.24+00 G

AM A AIR COMPRESSOR FAILS TO START N L 1.27-01 9.65-02 1.25-01 1.63-01 1.30+00 G

AM F AIR COMPRESSOR FAILS TO RUN H L 2.48-03 2.74-05 5.09-04 9.49-03 1.86+01 G

AR F AIR RECEIVER LOCAL FAULTS H L 6.00-07 1.04-08 1.56-07 2.32-06 1.49+01 G

AV CN AIR-OPERATED VALVE FAILS TO OPERATE;OPEN OR SHUT N L 2.20-03 3.06-04 1.42-03 6.62-03 4.65+00 G
AV KR AIR-OPERATED VALVE SPURIOUS OPERATION H L 3.02-06 1.46-07 1.27-06 1.11-05 8.70+00 G

B1 F >4 KV BUS FAULT H L 6.50-08 2.85-09 2.62-08 2.41-07 9.19+00 G

B2 F <4 KV BUS FAULT H L 1.32-07 3.59-09 4.27-08 5.07-07 1.19+01 G

BA F 120 V BUS FAULT H L 1.32-07 3.59-09 4.27-08 5.07-07 1.19+01 G

BC F BATTERY CHARGER NO OUTPUT H L 7.60-06 2.84-07 2.84-06 2.85-05 1.00+01 G

BD F DC BUS FAULT H L 6.50-08 2.85-09 2.62-08 2.41-07 9.19+00 G

BT D BATTERY NO OUTPUT (DEMAND) N L 6.61-03 7.12-04 3.88-03 2.12-02 5.45+00 G

With permission of Science Applications International Corporation.

 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
The In-Plant Reliability Data Base for Nuclear Plant Components
SPONSOR/AUTHOR: NO.:
USNRC-RES 4.6-11
INDUSTRY: TIME FRAME:
Nuclear 1975 to 1984
TYPE: FREQUENCY OF UPDATE:
Data Base and Reports None
NUMBER AND TYPE OF RECORDS: Corrective maintenance records: 4000 for
pumps; 5812 for valves; 698 for electrical failure rates and modes.

DATA BOUNDARY: Pumps, valves, diesels, battery charger, and inverters from
4 nuclear power plants.

DATA ACCESS:

Report ordering address: NTIS, Springfield, VA 22161

Phone: (703) 487-4650
Report cost: $19.95 each

DESCRIPTION:
The main objective of the In-Plant Reliability Data System (IPRDS) was
to develop a comprehensive and component-specific data base for PRA and
other component reliability-related statistical analysis. Data base personnel
visited selected plants and copied all the plant maintenance work requests.
They also gathered plant equipment lists and plant drawings and in some cases
interviewed plant personnel for information on component populations and
duty cycles. Subsequently, the maintenance records were screened to separate
out the cases of corrective maintenance applying to particular components; these
were reviewed to determine such things as failure modes, severity, and, if
possible, failure cause. The data from these reports were encoded into a
computerized data base.

Three reports have been issued containing IPRDS failure data. Information
on pumps, valves, and major components in NPP electrical distribution systems
has been encoded and analyzed. All three reports provide introductions to the
IPRDS, explain failure data collections, discuss the type of failure data
in the data base, and summarize the findings. They all contain comprehensive
breakdowns of failure rates by failure modes with the results compared with
WASH-1400 and the corresponding LER summaries. Statistical tables and plant-
specific data are found in the appendixes . Because the data base was developed
from only four nuclear power stations, caution should be used for
other than generic application.

Allthe documents in this series have numbers beginning with NUREG/CR-, followed
by these report-specific numbers: 2886 for pumps, 3154 for valves, 3831 for
electrical, and 2641 for the methodology report.
 Example Data Sheet
for Nuclear Plant Components
Iii-Plant Reliability Data Base
Data Resource 4.6-11
Ttble A. 22. In-plant r e l i a b i l i t y data system — service water booster pump
Failure rates by f a i l u r e node

Plant No. 1 Component class: pimps Population: 4

Plant type : PfR 1st subclass: alternating Average annual demands: 12
Operating period: 5 years 2nd subclass: centrifugal Average duty cycle: 60 (C)
3rd subclass: motor Number of failures: 32
4th subclass: service water Population hours: 110,000
booster Population demands: 240
Maintenance frequency: 1.8E-4/h

Time-related f a i l u r e rate, X Demand-related f a i l u r e rate, Q.

d
Failure mode Failure
Failures/10* h Failures/10 1 cycles
breakdown population Failures Failures
Low Recommended High Low Recommended High

Catastrophic 6
Fails to start 1 0.21 4.2 20
Fails while running 5 18 45 95
Degraded 6 6 24 55 110 6 11 25 49
Incipient 20 20 120 180 260 20 55 83 120

Failure
Failure Repair time a
Failure cause
population
breakdown (code) population
(%) Population Low Mean High

Seal/packing (3) 16 52 16 1.0 16.8 40.0

F i l t e r / s t r a i n e r plugged (21) 7 23
Control c i r c u i t (37) 2 7 2 8.0 14.0 20.0
Unknown (O) 2 7
Bearing (1) 1 3 1 1.5
Motor (27) 1 3 1 20.0
Switch (28) 1 3 1 4.0
Leaky f i t t i n g (35) 1 3 1 2.0

°Average time = 10 h; maximum time = 40 h; minimum time = 1.5 h.

 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
IEEE Standard 500-1984
SPONSOR/AUTHOR: NO.:
IEEE 4.6-12
INDUSTRY: TIME FRAME:
Nuclear Varies
TYPE: FREQUENCY OF UPDATE:
Data Base and Report Every five years
NUMBER AND TYPE OF RECORDS: Over 100 data sheets, containing failure
rate estimates for various failure modes and some repair times.

DATA BOUNDARY: Electrical, instrumentation, and mechanical components in

nuclear power plants

DATA ACCESS:
Report ordering address: IEEE Service Center
445 Hoes Lane, Piscataway, NJ 08854
Report cost: IEEE Member-$121 . 50; Nonmember-$135 . OO
Report accessibility: No restrictions

DESCRIPTION:
The IEEE Standard 500 document was originally issued in 1977 as a manual
of reliability data on electrical, electronic, and sensing components. Since
that time, data have been gathered on mechanical equipment reliability, making
the 1984 version of IEEE Std 500 a more comprehensive work by including data
on over 1,000 components. The primary source for the reliability data presented
in IEEE Std 500-1977 was the judgement of nearly 200 experts on component
reliability in the nuclear power field. The Delphi method was used to compile
and refine the expert opinion data. This information is included in IEEE Std
500-1984 for the nonmechanical components, but it is supplemented by data
from 24 additional sources. These include nuclear industry data from published
reports such as LER, NPRDS, and IPRDS data summaries and various manufacturers,
utilities, and plants as well as component data from U. S. military sources.
Therefore, the data developed represent either recorded data or the best
collective judgment of a group of specialists. In each case, the source
of the data is clearly identified. IEEE Std 500-1984 contains little unique
data .

The IEEE Std 500 document is based on a hierarchical structure of component

types set down in the manual's table of contents. The preface for each
subsection (defined by a component type) provides a tree diagram that clearly
shows the way the component classes have been subdivided to determine "data
cells". The failure modes for each component class are also hierarchically
organized according to failure severity: catastrophic, degraded, or
incipient. Rates per hour and demand rates {per cycle) are both included, as
well as upper and lower bounds.
 REF
(t) REPAIR TIME OR (§) RESTORE

HIGH
(•) OUT OF SERVICE

480.0
(HOURS)

9.76
REC
DieS el

0.25 t
1L3.1

LOW
REF
SUBSECTION:

HIGH
FAILURES/103 CYCLES

528

528

528
REC

18.2

18.2
18.2
0.30

0.30

0.30
LOW

n
Iu
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nig D
ve
irsr) F
LU
AIRE RATE
REF

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I
i
I
I
H
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. 73
. 73
. 73
. 354.
SECOTIN: U. 3 Genoeart Sest
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F
L
A
UIR
E1
S
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0.84
0.17
0.17

0.17
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0.17
1.18

0.02

0.02
0.02

0.06
0.02
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0.10
© 1
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 NON-PROCESS EQUIPMENT DATA BASES
TITLE: Generic Data Base for Data and Models Chapter of the National
Reliability Evaluation Program Guide

SPONSOR/AUTHOR: NO.:
USNRC-RES 4.6-13
INDUSTRY: TIME FRAME:
Nuclear Unknown
TYPE: FREQUENCY OF UPDATE:
Data Base and Report None
NUMBER AND TYPE OF RECORDS: Estimates of hourly and per demand failure
rates for 20 categories with error factors generated by experts

DATA BOUNDARY: standard nuclear plant PRA equipment list

DATA ACCESS:
Contact: EG&G Idaho, Inc.
P . O . Box 1625, Idaho Falls, ID 83415
Report ordering address: Same as above
Report cost : Unknown

DESCRIPTION:
In April 1982, a data workshop was held to evaluate, discuss, and critique
data in order to establish a consensus generic data set for the USNRC-RES
National Reliability Evaluation Program (NREP) . The data set contains
component failure rates and probability estimates for loss of coolant accidents,
transients, loss of o f f s i t e power events, and human errors that could be
applied consistently across the nuclear power industry as screening values
for initial identification of dominant accident sequences in PRAs. This
data set was used in the development of guidance documents for the performance
Of PRAs.
Data Resource 4.6-13
National Reliability Evaluation Program Guide
Example Data Sheet

TABLE I. (continued)

Nominal Error
Component and Failures Modes Value Factor Remarks
4.5 4 transformers
4 . J.] AU modes lE-6/hr 3
4.6 emergency Diesel (Complete Plant) Engine frame and associated moving parts,
4.6. I Failure to start generator coupling, governor, static
4 . 6 . 2 Failure to run, given start exciter, output breaker, lube oil system,
(emergency conditions) lE-3/hr 10 fuel oil. intake and exhaust air. start-
ing system; excludes starting air compres-
sor and accumulator, fuel storage and transfer, load
sequencers, and synchronizers. Failure to
start is failure to start, accept load,
and run for 1/2 hour; failure to run is
failure to run for more than 1/2 hour, given
start.
4.7 Relays
4 . 7 . 1 Contacts fail to transfer
(open or close) lE-4/d 10
4 . 7 . 2 Coil failure (open or short) lE-6/hr 10
4. JJ I hue Delay Ue I ays
4 . 8 . 1 Premature transfer lE-4/d 10
4 . 8 . 2 Fails to transfer
4 . 8 . 2 . 1 nimetanic 5E-6/hr 3 Non-consensus source. Data source is Mh -HIMK 21/Ii.
4.8.2.2 Other Fail-to-transfer rates are not currently
available for non-bimetallic time delay
relays.
 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
Offshore Reliability Data Handbook
SPONSOR/AUTHOR: NO.:
OREDA Committee 4.6-14
INDUSTRY: TIME FRAME:
Offshore Oil 1982 to 1984
TYPE: FREQUENCY OF UPDATE:
Data Base and Report None to date of this book
NUMBER AND TYPE OF RECORDS: Failure rates based on 14,000 failures for
300 component types. Mean values, upper and lower bounds are offered for
different failure modes.
DATA BOUNDARY: offshore oil equipment data and boundaries for safety
systems, process systems, electrical systems, utility systems, cranes and
drilling equipment.
DATA ACCESS:
Report ordering address: OREDA, P.O. Box 370, N-1322 HOVIK, Norway
Report cost: $150

DESCRIPTION:
The Offshore Reliability Data (OREDA) project began in 1982 as a Norweigan
government effort to survey and evaluate existing data banks so that the best
elements could be incorporated into a plan for offshore oil industry data
collection. The operational phase of this project in 1983 was managed
and funded by the OREDA Steering Committee, composed of oil company members.
All the member companies contributed funds for the project which involved
the monitoring, compilation, analysis, and presentation of data gathered
from the individual companies. The results of the program were published in
1984 as the OREDA Handbook.

The OREDA Handbook is structured by the type of systems (safety, process, etc.)
Components are cited beneath these headings and levels are designated by numeric
subdivisions, such as 4.2.1 and 4.2.2, much like IEEE Std. 500-1984. A preface
section precedes each system and each component type data page set. This
system parameters to be considered are listed. A full structured taxonomy,
including components and subclasses numerically identified, is also provided.
Each component level preface describes a variety of parameters including
operating mode, component specifications, and a diagram showing the component
boundary. The data table pages all employ the same format in which the heading
provides component information (operating hours, component population, etc.)
and the body presents the failure and repair data. Mean values for failure
data and upper and lower bounds are correlated to failure modes structured
much like those in IEEE Std. 500-1984, except that the "Catastrophic" severity
category is called "Critical" by OREDA. Repair time is given for each mode
as well.
Data Resource 4.6-14
Offshore Reliability Data (ORED A-84)
Example Data Sheet
Reprinted from ORED A-84, with permission.
Copyright © 1984 by OREDA Participants

Taxonomy no. and item External environment

1.3.1.1 Engine, gearbox and controls installed in
Safety Systems ventilated and heated modules. Steel tube
Fire-Fighting Systems protects pumps and drive shaft. Saline at-
Fire Water Pumps mosphere.
Diesel Motor, Gear/Shaft Driven Pumps
Testing and maintenance
Description Weekly: Check coolant and oil levels.
Multistage centrifugal pumps driven by Test run and check for leaks.
diesel engine. They are driven through a 3 months: Change oil and filter elements,
right angle gear box on approximately half clean magnetic plugs, check engine mani-
of the population, and through a straight fold and water pump for leaks, lubricate,
vertical gear box on the rest. Battery/mo- clean crankshaft vent valve.
tor start with air or hydraulic motor back- 6 months: Increasingly stringent mainten-
up. Automatic start from pressure drop in ance.
fire main with alternative manual facilitiy.
Typical output 450 mVh and 700—1500 Failure causes
mVh, 120-15Om head. Start failures predominantly on instrumen-
tation. Running failures on seals, bearings,
Application drive components and instruments.
Feeds the fire-water ring main on platform
with water from the sea, Item boundary specification
Only failures within the boundary indicat-
Operational mode ed with the dash line in the figure below
Standby, intermittent operation. are included in the reliability data source.

Internal environment
Sea-water.

DiM«lfu«i COOIm
M»i<»tion9

command Stwt Mart«r Cna.0*

V«n«l pan* Engine
G«M
boi

flhMMI
ly*t«m
Pump

•ound*ry tofet HoIAtIn9 van*

ItOUiIn9 *«!»• OuU«i

fig 4JO
Taxonomy no Item
1.3.1.1 Safety Systems
Fire-Fighting Systems
Fire Water Pumps
Diesel Motor, Gear/Shaft Driven Pumps

Population Samples Aggregated time ia service (10* hours) No of demands

17 10 Calendar time " Operational time T 1135
3826 .0002
Failure rate (per I O6 hrs) Active Repair (manhours)
Failure mode No of repair
failures Lower Mean Upper (hours) MIn Mean Max
Critical W* 120 210 310 86
13 t 26000 47000 78000
Failed to start 75 * 100 190 290 24 86 120
9t 6200 32000 69000
Failed while running 5* 2.0 23 51 3 93 130
4t 4600 15000 36000
Degraded 24 * 30 71 120 180
3t O 14000 45000
High temperature 22 * 22 66 120 6 190 400
3 t O 14000 44000
Low output I* 0.14 2.6 12
Unknown 1 * 0.14 2.6 12 96
Incipient 30 * 56 150 250 15
2Of 41000 81000 130000
Vibration 1 * 0.0092 3.6 15 46
It O 3800 19000
Leakage 20 * 13 71 140 Il 15 17
IO t 7100 35000 73000
Unknown 9* 0.20 77 160 I Il 12
9 t O 42000 MOOOO
Unknown 169 * 270 400 550 - 72
9t O 37000 86000
Failed 169 * 270 400 550 3 72 95
9 t O 37000 86000

All modes 303 * 680 840 1000 - - 81 -

45 t 87000 180000 280000

Comments
On demand probability (per 1000 demands). Lower : Mean : Upper
Critical - Failed to start: 0.37 : 50 ; 130

Note: The estimates were in some cases based on different subsets of samples for the different failure modes.
This results from tests of statistical consistence among samples., see sect 3.4.
 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
RADC Non-Electronic Reliability Notebook
SPONSOR/AUTHOR: NO.:
Rome Air Development Center 4.6-15
INDUSTRY: TIME FRAME:
Military July 1982 to August 1985
TYPE: FREQUENCY OF UPDATE:
Data Base and Report None

NUMBER AND TYPE OF RECORDS: Failure rates based on operations and

maintenance records and industry-wide sources

DATA BOUNDARY: Covers 250 non-electronic part types such as actuators,

complings, filters for 12 classes of environment (air, ground, sea) used in
military systems and equipment.

DATA ACCESS:
Contact: James A Collins, RADC Griff iss AFB, NY 13441-5700
Phone: (315) 330-4810 or 4726
Report order address: National Technical Information Service (NTIS)
Springfield, VA 22161
Phone: (703) 487-4650
Report No.: AD/A163 900
Report cost: $50.95
DESCRIPTION:
The objective of this notebook was the collection, analysis, and presentation
of nonelectronic component failure data and the presentation of analytical
methods that form the state-of-the-art in nonelectronic reliability
analysis. This report replaces the former Nonelectronic Reliability Notebook
(RADC-TR-75-22) .

This notebook is divided into six sections: Introduction, Applicable

Statistical Methods for Nonelectronic Reliability, Reliability Specifi-
cations, Special Application Methods for Reliability Prediction; Part Failure
Characteristics, and Reliability Demonstration Tests. Data is located in
section 5.0 on Part Failure Characteristics. This section describes the
results of the statistical analyses of failure data from more than 250
distinct nonelectronic parts collected from recent commercial and military
projects. This data was collected in-house (from operations and maintenance
reports) and from industry wide sources. Tables, alphabetized by part class/
part type, are presented for easy reference to part failure rates assuminng
that the part lives are exponentially distributed (as in previous editions
of this notebook, the majority of data available included total operating
time, and total number of failures only) . For parts for which the actual life
times for each part under test were included in the database, further tables
are presented which describe the results of testing the fit of the exponential
and Weibull distributions.
Data Resource 4.6-15
RADC Non-Electronic Reliability Notebook
Example Data Sheet

BAHERY
! FAILURE RATE PER MILLION HRS. !
COMPONENT APPL USER POINT 40% UPPER 2OX LOUER 807. UPPER I OF I OF OPERATING
PART TYPE BW CODE ESTIWTE SINGLE-SIDED IKTERWL IKTERWL RECS FAIL HRS (E4)

RECMRGEABLE A C 0.159 1 O 5.740

RECMRGEABlE A M 348.852 342.921 355.955 3 2810 8.055
RECMRGMlE AUT C 248.851 238.745 259.459 1 433 1.740
RECHARGEABLE 0OR C 0.004 0.003 0.014 1 2 313.175
RECHARGEABLE DOR M O. OU 0.013 0.022 3 12 732.544
RECMRGEABLE GF ? 1.630 1.302 2.044 3 18 11.042
RECMRGWBLE GF M 1.498 1.046 2.138 1 8 5.339
RECMRGEABLE GM M 15.748 4.404 34.040 2 2 0.127
RECMRGBWLE HEL M 674.768 434.344 720.148 2 201 0.297

BEARING
! FAILURE RATE PER MILLION HRS. !
COHPONEKT APPL USER POINT 4OX UPPER 2(T/ LOUER 8OX UPPER I OF ft OF OPEfWTING
PART TYPE BU CODE ESTIMATE SINGLE-SIDED INTERWL INTERVAL RECS FAIL HRS (E4)

BALL A C 1.372 0.272 4.171 1 1 0.729

WLL A M 5.133 4.787 5.507 2 158 30.784
BALL AI M 4.829 3.799 4.148 1 14 3.313
BALL AIF M 19.323 9.843 35.795 3 3 0.155
BALL AIT M 0.723 1 O 1.247
BALL DOR M 0.010 0.007 0.014 3 9 903.040
8ALL GF C 13.985 10.003 19.511 1 9 0.443
BALL GF M 1.148 1.001 1.319 8 44 38.320
BALL GM M 0.094 0.054 0.159 1 4 42.554
BALL HEL M 13.398 10.943 14.408 2 22 1.442
BALL NS M 0.053 1 O 17.134
BALL NSB M 4.728 1.923 10.220 1 2 0.423
BALL SF M 0.688 2 O 1.332
 NON-PROCESS EQUIPMENT DATA BASES
TITLE:
Reliability Prediction of Electronic Equipment (Military Handbook 217E)

SPONSOR/AUTHOR: NO.:
RADC 4.6-16
INDUSTRY: TIME FRAME:
Government and Military
TYPE: FREQUENCY OF UPDATE:
Data Base and Report Every 12 to 18 months

NUMBER AND TYPE OF RECORDS: Failure rates for 13 categories of

components .

DATA BOUNDARY: Electronic components used in military electronic systems

and equipment .

DATA ACCESS:
Contact: Anthony Fedducia
Rome Air Development Center
Attn: RBET
Griffiss Air Force Base, NY 13441
Phone: (315) 330-4921
Report cost: None
Report accessibility: Unrestricted

DESCRIPTION:
Military Handbook 217E (MIL 217E) establishes uniform methods for predicting
the reliability of military electronic equipment and systems. There are two
methods of reliability predictions, namely parts count and parts stress
analysis .

The part stress analysis prediction section contains failure rate models for
a broad variety of parts used in electronic equipment. This method includes
the effects of part quality factors and environmental factors. The tabulated
values of the base failure rate are "cut off" at the design temperature and
stress of the part.

The parts count method is suitable for early design phase reliability
prediction. The method uses information on generic types, quality levels,
and environment. The latter two effects are considered with the application
of specified factors. The failure rates for both methods are calculated using
the same generic expressions.

The military electronic components are subdivided into 13 categories. Generic

failure rates for these categories are derived by applying single-value factors,
such as part quality level and operating environment. The tabulated base
failure rates are terminated at the rated design temperature and material stress
of the part. The handbook provides example failure rate calculations for all
of the categories considered as well as for miscellaneous related parts.
Maintenance information is covered by a separate program, which uses data from
MIL 470 for equipment testing and MIL 471 for prediction of maintenance.
Data Resource 4.6-16
Military Handbook 217E
Example Data Sheet

MIL-HDBK-217E
CAPACITORS CAPACITORS
MIL-C-55514, CFR

SPECIFICATION STYLZ DESCRIPTION

MIL-C-55514 CFR Plastic, Metallized Plastic, ER

Part operating failure rate model (Xp):
>p » X^ (ir£ x if x if ) failures/10 hrs.

where the factors are shown in Tables 5,1.7.1-28 throuqh -33.

TABLE 5-1.7.1-23
Environmental Mode Factors

ENVIRON- *E ENVIRON- *E
MENT MENT

GB 1 SF 1
1.1 MfF 11
3? 1.9 MFA 15
GM 9.3 USL 31
Mp 11 ML 36
NSB 5 CL 610
NS 5.7
NU 16
Table 5.1.7.1-29
NH 16
Bas« Failure Rate Tables
NUU 17
for Capacitor Spec and* Style
A
RW 23
Spec S Table
AIC 3.5
MIL-C Style Number
AIT 6.5
AIB 9.5 55514 Char. M, N 5.1.7.1-32
AIA 6,5
AIF 15
Char. Q. R, S 5.1.7.1-33
AUC 10
AUT 20
AUB 25
AUA 20
AUF MO